Heat reclamation and air circulation device

ABSTRACT

A device for reclaiming heated air near the ceiling of a room by circulating it to the lower portions of a room which reduces thermal stratification and distributes warm room air, which, improves comfort and heating efficiency, and in cooling mode, can be turned 180 degrees in the vertical plane to move cool air from the floor to the ceiling. Suspended from the ceiling by a small hook, the lightweight double walled fabric structure provides insulation against heat loss of the moving air, and contains a quiet and efficient fan at the bottom of the inner tube assembly which directs airflow into the room through a deflector crafted from a folded fabric sheet. The inner tube is held open against the negative pressure generated by suction of the fan by external springs attached to the outer wall of the inner tube, each spring fashioned from two struts connected by a short segment of elastic polymer.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a non-provisional and claims the priority benefit of U.S. provisional application Ser. No. 61/922,386 filed Dec. 31,2013, and U.S. provisional application Ser. No. 61/940,844 tiled Feb. 18, 2014. The entire contents of both applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems for moving air in a building. More particular, the present invention relates to ducting systems to move air vertically but not limited thereto.

2. Description of the Prior Art

The invention is in the class of devices for generating air flow within a building structure or room, and having an upright air duct. Warm air rises to the cooler ceiling where the heat is conducted through to the next floor or roof. The greater the temperature differential between the ceiling and the air just beneath, the greater the rate of heat loss. Bringing the heated air to the floor level thus lowers the rate of heat loss, and may lower heating requirements overall. By increasing the circulation of warm air, especially within homes featuring a secondary point source of heat such as gas or wood stove, reductions in the demand for the primary heating system and additional point heating devices such as an electric heater, may be realized. In homes with central heating broken into several zones, heating requirements can be lowered in one or more zones by improved warm air circulation, and the need for additional point heating devices reduced or eliminated.

With respect to hot weather, cool air is denser than warm air, and so pools at floor level while warm air rises above. Bringing cool air from the floor up toward the ceiling allows it to mix with the warmer air, improving overall comfort and reducing the load on air conditioning systems.

Previous devices have bees made to perform the described functions, typically consisting of a structure installed on the floor or wall and projecting a rigid tube upward, such as U.S. Pat. No. 3,173,353. One device is suspended from the ceiling pushing air downward towards the floor in U.S. Pat. No. 4,185,545 and using a suspended duct of a “yieldable” mature, and ceiling fans also can move air in both directions. However these designs have significant constraints when applied to dwellings; either a device resting on the floor that must be fixed in place, a suspended system with a fan in the upper part of the duel close to the ceiling, requiring significant support, and relying on a circular motion of the lower tube to distribute air as well as an existing or installed ceiling electrical outlet. A ceiling fan is likewise fixed m place and also requires installation and a ceiling power supply. These are constraints and expenses that many consumers might find objectionable. Previous warming devices using a fan mounted at the ceiling, may be additionally compromised by lower efficiencies and greater noise generated by a fan pushing air downwards through a tube. Such a configuration is less efficient than a similarly sized fan at the bottom of a tube pulling air downwards, which can therefore be sized smaller, turn at a slower rpm, is easily powered by low voltage DC power from any wall outlet, and in general is less intrusive than single fan mounted at the top.

SUMMARY OF THE INVENTION

A suspended, lightweight, double walled fabric tube, heat reclamation and air circulation device of the present invention can be supported by an attachment device, such as a single small hook screwed into the ceiling of any room. It operates by pulling down warm air from beneath the ceiling and distributes it closer to the floor using a low-energy fan. Rotated 180 degrees in the vertical plane, the device will also bring cool air from the floor up to the ceiling, providing a cooling function. The outer wall of the double wall fabric tube provides insulation against heat or cooling loss and a pleasingly stable, translucent surface for incorporating lighting and artistic design embodiments. Within the outer tube wall and applied to the outer wall of the inner tube, are external springs holding open the inner fabric tube, which allow case of construction and maintenance of structural integrity of the inner fabric tube despite negative pressure generated by fan suction. In a single fan configuration, this spring arrangement allows the fan to be placed at the bottom of the structure where it is more efficient in moving air, and therefore can be sized smaller, and run slower and quieter. In a dual fan, push-pull configuration where one fan is at the top and one fan at the bottom of the tube, the device can provide improved power without significant increase in noise and without increasing the size of the fan or device. A deflector made of fabric allows for the most favorable directionality of airflow.

The spring device is of particular use in a pliable, tubular structure under negative air pressure. The spring can be added alter construction or placement of the tube is complete, using heavy duty tape, slipped into a formed pocket, or by a few sutures if slight air leakage is not of concern. The spring, or a combination of a plurality of springs, allows full function of the tube under negative pressure without the need for embedding internal reinforcing rings, coils, or stents within the lumen of the tube, which may therefore be constructed of inexpensive and lightweight fabrics, extrusions, films, and other similar lightweight relatively air impermeable materials.

The deflector may be a folded fabric or paper-like material. It is particularly desirable due to very low weight, low cost, simple construction, and ease of attachment using elastic bands, tape, glues, staples, clips or other bonding methods. The design is ideal for use in an air recirculation device that would be suspended from a ceiling and must be very lightweight.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the device of the present invention as it would be installed within a room, single fan configuration.

FIG. 1 b is a side view of the device as it would be installed within a room, dual fan, push-pull configuration.

FIG. 2 is an enlarged side view of the upper assembly of the device.

FIG. 3 is an enlarged top view of the upper assembly of the device

FIG. 4 is an enlarged side view of a spring assembly used to hold open the inner tube.

FIG. 5 is an enlarged top view of a spring assembly used to hold open the inner tube.

FIG. 6 is an enlarged side view of the lower fan assembly.

FIG. 7 is a side view of the spring as it would be installed on the outside of a fabric tube and secured with tape.

FIG. 8 is a top view of the deflector in process of being made prior to folding, wherein 100 is the front of the deflector.

FIG. 9 is a side view of the deflector as installed at the discharge end of the recirculation device.

FIG. 10 is a rear view of the deflector as installed at the discharge end of the recirculation device.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referencing the accompanying drawings, in FIG. 1 a heat reclamation and recirculation device of the present invention is shown suspended by a small hook 1 screwed into the ceiling of a room. By using lightweight materials throughout the design, it is intended that the device will be suspended from any common ceiling material such as drywall, without requiring an anchor device beyond a small screw-in cup hook, and powered from below by a cord extending from the bottom of the device to a nearby wall outlet. For cooling, and powering the fan when the tube is rotated 180 degrees in the vertical plane, a parallel set of small power wires is affixed to the wall of the inner tube and ending in a power plug, in order to maintain a power connection at the bottom of the tube when placed in the new orientation. As the device has extremely modest electrical requirements, it is envisioned that a power source may ultimately be rechargeable batteries, or solar cells incorporated into the outer tube wall alone or in combination with each other.

In FIG 1 b, the device is shown in its dual fan, push-pull configuration with one fan mounted at the bottom of the tube, and another mounted at the top.

Notably, the device incorporates a dual tube comprising an outer tube 8 and an inner tube 7 with the outer tube and spaced therefrom, which provides insulation of the warm air traveling down the inner tube, improving efficiency, and conceals unappealing deformities in the inner tube caused by fan generated negative pressure or air turbulence, and provides a platform for artwork and translucency for lighting. Thus, the device blends both utility and esthetics where previous devices did not.

In working mode, warm air close to the ceiling is drawn into the opening of the upper cylinder 3 by suction generated from a horizontal, high efficiency, low noise DC electric fan, commonly used for cooling computers, 11 located at the bottom of the inner tube, or at each end in dual configuration for additional power, or even segmentally for tubes that extend to greater heights. For cooling, the duct 14 can be removed and the inner tube pulled from its outer covering tube, rotated 180 degrees and placed back in the outer tube so when the device is suspended again, air would be pulled upwards from the lower level of the room. The device is light enough to attach by a thin line 2 of twine, wire, monofilament line or equivalent, secured tightly across the upper and/or lower cylinders 3, 13, which are constructed from a cardboard, fiber resin, or plastic core. The inner tube is ideally made from a thin, lightweight non-woven fabric made from polyethylene such as Tyvek® or polypropylene based material such as Typar®, although any non-woven, or woven fabric that can be formed into pliable, lightweight sheets with low air permeability, or lightweight, flexible tubing of plastic or other material may be used. The fan may be an Arctic F9 fan with fluid bearings available from Arctic AG of Switzerland but not limited thereto.

The fabric is formed into tubes using a transfer adhesive applied to the edge but may be sewn or bonded by thermal or ultrasonic means, glues, or any suitable bonding process appropriate to the material used. Materials extruded into large diameter, thin wailed, flexible tubes may ultimately be used—and preferred—if costs can be lowered.

The outer tube 8 is made from materials similar to the inner tube, or in an artistic expression, any material or design that is lightweight and able to be supported by the inner tube assembly. In its preferred design, for designs incorporating relatively stiff materials or graphics sensitive to folding or creasing, the outer tube is formed by connecting the edges of a sheet, by means of a lightweight zipper or other binding method that permits the return of the tube to sheet form, and back again to a tube. This allows the fabric sheet to be roiled into a compact roll for packaging, shipping, and storage, and avoids creases, wrinkling, or damage to the tube material or graphic embellishments. This also allows an exchange of the outer tube by the consumer to an outer tube with a different artistic design, so as to accommodate a change in decor, tastes, or mood. Alternatively, for materials such as soft type 14 Tyvek, fabrics and designs less vulnerable to such creasing and damage, the outer tube may be formed in a similar fashion to the inner tube.

Support elements 4 that may be formed of small foam blocks, a full length piece of foam, or length of thick cord, for example, are attached inside the top and bottom of the inner wall of the outer tube using a transfer adhesive or double sided tape. The outer tube is supported by this attached support element 4 which rests on a foam collar 5, 12 that tits tightly to the upper and lower cylinders, and is in turn supported by Motion against the walls of the upper and lower cylinders, and tape 6 used to secure the inner tube to the cylinders. The foam collars are also used as a surface and platform to mount lighting, electronics and controls.

Each of the plurality of springs 9 is formed from two rigid struts 16 approximately equal in length to the diameter of the inner tube, connected by a short tube of rubber 18 or other suitable interface component, and attached to the outer wall of the flattened inner tube using strips of heavy duty tape 15, 17 or slipped within pockets created on the tube wall. When released the springs hold the walls of the inner tube open in a triangular shape as shown in FIG. 5. The rigid struts are made from common wood dowels, however any rigid and lightweight material, in rod, tubular form or flats, including metals, fiberglass, carbon fiber or common plastics may be used. The struts are connected by an external segment of rubber or a memory type elastic polymer, although a wire spring could also be used. A solid rod of rubber or elastic polymer may also be inserted into the ends of two tubular struts, the principle in all instances being to have a flexible material with spring memory connecting and maintaining the two struts in a straight line when the spring assembly is not under strain. Thus, when the spring assembly is bent in the middle to form two sides of a triangle and secured to two thirds of the outer walls of the inner tube, it will exert a counterforce sufficient to hold open the fabric walls of the inner tube when it is under negative pressure from fun generated suction, the third side of the triangle being formed from the wall of Inner tube under tension between the outermost ends of the two struts. A singular “V” shaped piece of lightweight thermoplastic or metallic spring may also be used and preferred In a high production environment. Tape, heat, ultrasonic welding or other suitable and convenient attachment element may be used to join the components of the device together in an inexpensive manner.

The lower portion of the inner tube is taped securely to upper cylinder 10 of the fan assembly. Tape may also be used to connect the fan 11 between the upper cylinder of the fan assembly and lower cylinder 13. The lower foam collar 12 is fitted tightly over the lower cylinder As detailed in FIG. 6, a modular DC plug may be fitted through the lower collar and the fan, uplighting, and other electronics such as a built in timer, wireless receivers for lighting controls, parallel power wiring for another power plug, fan speed control, and a remote thermostat are connected. The DC fan is very quiet and efficient, and at current per kW prices costs less than 0.20 per month when run continuously in a single fan configuration. While a switch is therefore optional and not necessary, it is envisioned a wireless thermostat may be placed in proximity to a point source of heat, thereby turning on the device when the heat source is on. As the device is best placed away from the heat source and it can take a prolonged time for the heat to reach the upper part of the device, it is preferable for the device to begin actively pulling the warm air towards the ceiling intake well before the warm air reaches a thermostat placed within the tube on its own.

At the very bottom of the fan assembly, a fabric air deflector scoop 14 is secured by Velcro®, a removable elastic band, tape, glue, clips, or other adjustable, removable, or permanent method to the bottom of the lower cylinder. The scoop incorporates a thermometer display to provide evidence and feedback to the customer, of the device's performance. The folded deflector is preferably constructed from a fabric sheet of a non-woven material such as Tyvek, but may be made from any material in sheet form with sufficient inherent softness such as paper, cardboard, or plastic film, and that can be die cut or stamped for production.

FIG. 8 shows the deflector as prepared for construction. The front 100 of the deflector 14 is facing the top of the drawing. There are two cuts 60 at the rear comers extending towards the middle of the sheet that allow shaping the deflector without creating hard creases. FIG. 9 and 10 show further steps of construction of the deflector. The deflector shape is made by bringing the rear corner 50 of the right tab 40 behind the rear tab 90 so the right tab edge 30 is touching and lined up with the rear tab edge 80, and the front corner 20 of the right tab overlays the right corner of the rear tab 90. The process is repeated with the left tab 101, and a small piece of tape or heat bonding used to secure the side tabs together where they cross in the middle of the rear of the deflector, and on their leading edges. The formed deflector is then placed around the bottom edge of the inner tube 7. Once placed around the inner tube 7, the formed deflector may be secured in position with Velcro®, an elastic band, or tape 120 that covers the folded tabs and a portion of the tube. Depending on the desired exhaust angle, the angle of the cuts 60 and the geometry of the side tabs and front of the scoop may be easily adjusted.

While the present invention has been described with respect to a specific embodiment or embodiments, it is to be understood that one of skill in the art will be able to create reasonable variants. All equivalents are deemed covered by the invention as defined by the following claims. 

What is claimed is:
 1. A reversible heat reclamation and air circulation device comprising: a double-walled tube including an inner tube and an outer tube, and upper and lower foam collar disks that provide mounting for uplighting, down lighting and electronics outside the inner tube so as not to adversely affect air flow and provide for simple construction and end user applied upgrades.
 2. The device of claim 1, wherein the double-walled tube is formed of a soft, pliable, translucent, lightweight tube material.
 3. The device of claim 1, wherein the fan is mounted at the bottom of the tube for efficiency, quiet operation, and ease of powering from a wall outlet.
 4. The device of claim 1, wherein a fan at the bottom and the top of the tube, or multiple fans in segmental fashion will provide additional power without increase in size.
 5. The device of claim 1, wherein the air conducting inner tube assembly is constructed using a series of lightweight cylinders and fabric tubes that can be attached using tape.
 6. The device of claim 1 further comprising external springs to maintain the inner-walled tube open during operation.
 7. The device of claim 1 further comprising an origami-type folded piece of material to form a lightweight, durable, and adjustable air deflector which can be securely attached to a tube using an elastic band or tape.
 8. A spring device that provides for an external method to hold open a collapsible tube under negative pressure.
 9. The spring device of claim 8 compromising two rigid struts substantially equal in length to an outer diameter of an inner tube used as part of a conduit to transfer air, wherein the two rigid struts are connected by a short segment of elastic material, which is attached to the outer wall of the inner tube which has been flattened and wherein, when released, the springs hold the walls of the inner tube open, in a triangular shape.
 10. A device in the form of a sheet folded to form a lightweight and durable air deflector that is resistant to tearing and can be deformed or crushed and then retain its original shape without loss of function.
 11. The device of claim 10, wherein the deflector can be adjusted, yet securely attached to a tube using Velcro®, an elastic baud, or tape alone. 